Permeable nanoparticle reflector

ABSTRACT

An optically-responsive multilayer reflective article is formed by applying a dilute solution or suspension of metallic nanoparticles to an optically-responsive detection layer. The solution or suspension is allowed to dry to form a semicontinuous liquid- or vapor-permeable light-reflective layer that will permit a liquid or vapor analyte to pass through the light-reflective layer to cause an optically-responsive change in the detection layer in the presence of the analyte.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. Ser. No. 11/530,619, filed Sep.11, 2006, the disclosure of which is incorporated by reference in itsentirety herein.

This invention relates to reflective articles that includeoptically-responsive detection layers.

BACKGROUND

Various chemical, optical, or electronic detectors have been proposedfor sensing the presence of gases, liquids, and other analytes. Opticaldetectors, for example, have been provided that employ a detection layerwhich is made from a material that modulates or otherwise alterstransmitted or reflected light in the presence of an analyte. Reflectivelayers have been placed adjacent to the detection layer to guide lightinto or out of the detection layer. When an analyte is present, thedetection layer undergoes a responsive change in an optical property.Reflective layers may also provide an indication that the analyte ispresent (e.g., via optical interference). For example, a colorimetricchange may be provided in the presence of a vapor of interest by using athin-film multilayer indicator having a porous detection layer whoseoptical thickness changes in the presence of the vapor, located betweenreflective and semireflective layers at least one of which is permeableto the vapor of interest. One such indicator employs a porous detectionlayer located between a reflective layer and a vapor-permeablesemireflective layer and is described in U.S. Patent ApplicationPublication Nos. US 2004/0062682A1 (Rakow et al. '682) and US2004/0184948A1 (Rakow et al. '948).

SUMMARY OF THE INVENTION

Another such indicator employs a porous detection layer located betweena semireflective layer and a vapor-permeable reflective layer proximatesorbent media and is described in U.S. Patent Application PublicationNo. 2008/0063575A1 to Rakow et al. Both such indicators employ alight-reflective vapor-permeable surface adjacent a porousoptically-responsive detection layer. The light-reflective surfaces insuch indicators may be prepared for example via the initial depositionof a dense mirror using traditional metallization techniques (e.g.,sputtering, evaporative deposition, electroplating or otherelectrochemical deposition) followed by a subsequent perforation step(e.g., etching or laser ablation) to provide pathways for vaporpermeation into the detection layer pores. This approach, however,requires several exacting steps and specialized equipment. In addition,the deposition or perforation procedures may adversely affect theoptical response of the detection layer or may adversely affect otherlayers within the indicator structure.

The present invention provides, in one aspect, a method for forming anoptically-responsive multilayer reflective article. The method isrelatively simple to perform, and may be accomplished by applying adilute solution or suspension of metallic nanoparticles to anoptically-responsive detection layer and allowing the solution orsuspension to dry to form a semicontinuous liquid- or vapor-permeablelight-reflective layer that will permit a liquid or vapor analyte topass through the light-reflective layer to cause an optically-responsivechange in the detection layer in the presence of the analyte. Thelight-reflective layer may have somewhat lower reflectivity than atypical metallized mirror made using traditional deposition techniques.However, the disclosed method enables deposition of a liquid- orvapor-permeable light-reflective layer without requiring specializeddeposition equipment. The disclosed method is especially useful forforming a vapor-permeable light-reflective layer atop a porous detectionlayer.

The invention provides in another aspect an optically-responsivemultilayer reflective article that comprises an optically-responsivedetection layer in fluid communication with a semicontinuous liquid- orvapor-permeable light-reflective metal nanoparticle layer that willpermit a liquid or vapor analyte to pass through the light-reflectivelayer and cause an optically-responsive change in the detection layer inthe presence of the analyte.

These and other aspects of the invention will be apparent from thedetailed description below. In no event, however, should the abovesummaries be construed as limitations on the claimed subject matter,which subject matter is defined solely by the attached claims, as may beamended during prosecution.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic sectional view of a thin-film multilayer indicatorthat has a semicontinuous vapor-permeable semireflective metalnanoparticle layer in accordance with the present invention;

FIG. 2 is a schematic sectional view of a thin-film multilayer indicatorthat has a discontinuous vapor-permeable semireflective metalnanoparticle layer in accordance with the present invention;

FIG. 3 is a schematic sectional view of a thin-film multilayer indicatorthat has a vapor-permeable reflective metal nanoparticle layer inaccordance with the present invention;

FIG. 4 through FIG. 6 are schematic side sectional views of a thin-filmmultilayer indicator that is mounted in proximity to various sorbentmedia;

FIG. 7 through FIG. 9 are plots showing the response of variousthin-film multilayer indicators to a toluene challenge;

FIG. 10 and FIG. 11 are black-and-white renderings of colored wavefrontsmoving across thin-film multilayer indicators; and

FIG. 12 is a plot showing the response of a thin-film multilayerindicator to challenges from several vapors.

DETAILED DESCRIPTION

The terms set forth below are defined as follows:

“Liquid or vapor of interest” means an organic or inorganic liquid orvapor whose detection is desired, e.g., in ambient air or in a processatmosphere.

“Analyte” means the specific liquid or vapor of interest that is beingdetected, e.g., in a chemical or biochemical analysis.

“Optically-responsive” when used with respect to an article or adetection layer means that the article or detection layer exhibits aresponsive change in a detectable optical property when an analyte ispresent, such as a change in optical thickness (viz., physical thicknessor refractive index), reflectivity, phase shift, polarization,birefringence or light transmission.

“Reflective” when used with respect to a layer means that the layerreflects visible light.

“Semireflective layer” means a first reflective layer, which inreference to a second reflective layer, has lower reflectivity andgreater light transmission than the second reflective layer and whichmay, for example, be used in spaced relation to the second reflectivelayer to provide interference coloration.

“Vapor-permeable” when used with respect to a reflective layer one sideof which is in fluid communication with a detection layer means that ifthe other side of the reflective layer is exposed to an air streamcontaining 1000 ppm styrene monomer vapor flowing at 20 liters/min for15 minutes, sufficient styrene monomer will pass through the reflectivelayer so that an optically-responsive change takes place in thedetection layer.

“Liquid-permeable” when used with respect to a reflective layer one sideof which is in fluid communication with a detection layer means that ifthe other side of the reflective layer is exposed to a solutioncontaining 10% by volume acetone in water for 10 minutes, sufficientacetone will pass through the reflective layer so that anoptically-responsive change takes place in the detection layer.

“Porous” when used with respect to a material means that the materialcontains a connected network of pores (which may, for example, beopenings, interstitial spaces or other channels) throughout its volume.

“Size” when used with respect to a pore means the pore diameter for apore having a circular cross section, or the length of the longestcross-sectional chord that may be constructed across a pore having anon-circular cross-section.

“Microporous” when used with respect to a material means that thematerial is porous with an average pore size of about 0.3 to 100nanometers.

“Continuous” when used with respect to a layer of a material means thatthe layer is non-porous and is not vapor-permeable.

“Semicontinuous” when used with respect to a layer of a material meansthat the layer is porous and liquid- or vapor-permeable. Asemicontinuous layer may be vapor-permeable but not liquid-permeable.

“Discontinuous” when used with respect to a layer of a material meansthat the layer has at least two separate and distinct islands of thematerial within a given plane with empty space therebetween, or at leasttwo separate and distinct empty spaces (lakes) within a given plane withthe material therebetween, and that the layer is vapor-permeable.

“Nanoparticles” means particles having an average particle diameter ofabout 1 to about 100 nm.

The disclosed optically-responsive multilayer articles may be used todetect a variety of liquids or vapors of interest. Representativeliquids of interest include water, bodily fluids, oils, solvents, andother organic liquids. Representative vapors of interest include watervapor, gases, and volatile organic chemical compounds. Representativeorganic liquids and volatile organic chemical compounds includesubstituted or unsubstituted carbon compounds including alkanes,cycloalkanes, aromatic compounds, alcohols, ethers, esters, ketones,halocarbons, amines, organic acids, cyanates, nitrates, and nitriles,for example n-octane, cyclohexane, methyl ethyl ketone, acetone, ethylacetate, carbon disulfide, carbon tetrachloride, benzene, styrene,toluene, xylenes, methyl chloroform, tetrahydrofuran, methanol, ethanol,isopropyl alcohol, n-butyl alcohol, t-butyl alcohol, 2-ethoxyethanol,acetic acid, 2-aminopyridine, ethylene glycol monomethyl ether,toluene-2,4-diisocyanate, nitromethane, and acetonitrile.

Referring to FIG. 1, optically-responsive multilayer article 10 providesa thin-film multilayer indicator that can detect the presence of avariety of analytes. Article 10 includes a substrate 12, continuousreflective layer 14, optically-responsive detection layer 16 andsemicontinuous semireflective layer 18. Layer 14 may be formed using avariety of deposition techniques, including sputtering, evaporativedeposition, electroplating or other electrochemical deposition,lamination or applying a suitably thick layer of a metallic paint. Layer18 contains metal nanoparticles 20 arranged in a morphology whichapproximates a stack of cannonballs or marbles and through which liquidor vapor can permeate to reach detection layer 16, and is formed asdescribed in more detail below. An analyte in the form of a liquid orvapor of interest near (e.g., above) layer 18 can pass through pores 22into detection layer 16. Detection layer 16 can be formed in a varietyof ways and is made from a suitable material or made with a suitablestructure so that the layer's optical thickness changes (e.g.,increases) upon exposure to the analyte. The resulting optical thicknesschange brings about a visibly perceptible appearance change in article10. The change can be observed by looking at article 10 throughsemireflective layer 18. Ambient light represented by ray 24 passingthrough semireflective layer 18 and detection layer 16 is reflected byreflective layer 14 back through detection layer 16 and semireflectivelayer 18. If an appropriate initial or changed thickness has been chosenfor detection layer 16, and provided that layers 14 and 18 aresufficiently flat, then interference coloration will be created ordestroyed within device 10 and a visibly discernible change in theappearance of device 10 will be apparent when viewed throughsemireflective layer 18. Thus external equipment such as a powered lightsource, optical detector or spectral analysis would not be required toevaluate the condition of device 10, although such external equipmentmay be used if desired.

FIG. 2 shows a schematic sectional view of an optically-responsivemultilayer article 26 like article 10 in FIG. 1, but in which the metalnanoparticles 20 in layer 28 have been applied in stripes or dots withgaps 30 between islands of nanoparticles 20, or in a layer with emptyspaces or lakes 30 in a perforated layer of nanoparticles 20. Thestripes, dots or perforated layer 20 are individually semicontinuous andpermeable to liquid or vapor. Overall, layer 28 is discontinuous, andfor a given layer thickness and nanoparticle diameter can have greaterliquid or vapor permeability than layer 18 in FIG. 1 owing to thepresence of the gaps, spaces or lakes 30.

FIG. 3 shows a schematic sectional view of an optically-responsivemultilayer article 40. Article 40 includes a transparent substrate 42and indicator 44. Indicator 44 includes continuous semireflective layer46, porous detection layer 48 and semicontinuous liquid- orvapor-permeable reflective layer 50. Layer 50 contains metalnanoparticles 20 arranged in a morphology having sufficient thickness sothat layer 50 has greater reflectivity than semireflective layer 46,while retaining sufficient porosity so that liquid or vapor can permeatethrough layer 50 to reach detection layer 48. A portion of ambient lightrepresented by ray 49 a passes through substrate 42, is reflected fromsemireflective layer 46 as light ray 49 b, travels back throughsubstrate 42, and then passes outside substrate 42. Another portion ofambient light ray 49 a passes through substrate 42, semireflective layer46 and detection layer 48 and is reflected from reflective layer 50 aslight ray 49 c. Light ray 49 c travels back through detection layer 48,semireflective layer 46 and substrate 42, and then passes outsidesubstrate 42. If an appropriate initial or changed thickness has beenchosen for detection layer 48, and provided that layers 46 and 50 aresufficiently flat, then interference coloration will be created ordestroyed within indicator 44 and light rays like rays 49 b and 49 c,and a visibly discernible change in the appearance of indicator 44 willbe apparent when viewed through semireflective layer 46.

The disclosed device may be placed in proximity to a layer or body ofsorbent media, or to both a layer of sorbent media and a body of sorbentmedia. FIG. 4 through FIG. 6 show schematic side sectional views of avarious thin-film multilayer indicators in proximity to various layersof sorbent media. In FIG. 4, an organic vapor-containing air stream 72flows across indicator 60 above glass substrate 53. A small piece ofwoven carbon paper 74 placed against vapor-permeable metal nanoparticlereflective layer 66 provides a path for organic vapors in air stream 72to reach detection layer 55. Incident light rays such as ray 76 fromlight source 77 are reflected by semireflective layer 54 as firstreflected ray 78 a and by metal nanoparticle reflective layer 66 assecond reflected ray 78 b. FIG. 5 is similar to FIG. 4 but an organicvapor-containing air stream 72 reaches detection layer 55 through apiece of glass wool 84 placed against vapor-permeable metal nanoparticlereflective layer 66. FIG. 6 is similar to FIG. 4 and FIG. 5 but anorganic vapor-containing air stream 72 reaches detection layer 55through a piece of flexible microporous carbon-loaded nonwoven web 94placed against vapor-permeable metal nanoparticle reflective layer 66.

A variety of metal nanoparticles may be employed in the disclosedoptically-responsive multilayer reflective articles. Representativemetals include silver, nickel, gold, platinum and palladium and alloyscontaining any of the foregoing. Metals prone to oxidation when innanoparticle form (e.g., aluminum) might be used but desirably would beavoided in favor of less air-sensitive metals. The metal nanoparticlesmay be monolithic throughout or may have a layered structure (e.g., acore-shell structure such as an Ag/Pd structure). The nanoparticles may,for example, have an average particle diameter of about 1 to about 100,about 3 to about 50 or about 5 to about 30 nm. The overall thickness ofthe metal nanoparticle layer may, for example, be less than about 200 nmor less than about 100 nm, and the minimum layer thickness may, forexample, be at least about 5 nm, at least about 10 nm or at least about20 nm. Although large diameter microparticles might be applied to form amonolayer, the nanoparticle layer typically will be severalnanoparticles thick, e.g., at least 2 or more, 3 or more, 4 or more or 5or more nanoparticles, and with up to 5, up to 10, up to 20 or up to 50nanoparticles total thickness. The metal nanoparticle reflective layermay, for example, have a reflectance of at least about 20%, at leastabout 40%, at least about 50% or at least about 60% at 500 nm.

Solutions or suspensions of suitable metal nanoparticles are availablefrom several suppliers, including Inkjet Silver Conductor inkAG-IJ-G-100-S1 (from Cabot Printable Electronics and Displays);SILVERJET™ DGH 50 and DGP 50 ink (from Advanced Nano Products); SVW001,SVW102, SVE001, SVE102, NP1001, NP1020, NP1021, NP1050 and NP1051 inksfrom Nippon Paint (America); METALON™ FS-066 and JS-011 inks fromNovacentrix Corp. and NP Series nanoparticle paste from HarimaChemicals, Inc. The metal nanoparticles may be borne in a variety ofcarriers, including water and organic solvents. The metal nanoparticlesmay also be borne in a polymerizable monomeric binder but desirably suchbinder is removed from the applied coating (using e.g., solventextraction or sintering) so as to provide a permeable nanoparticlelayer.

Several of the above-mentioned commercial metal nanoparticle productshave been used as conductive paints or solder pastes for making circuittraces or joints. Typically the products are applied in theiras-received form to a nonporous substrate, and form a conductive layerof ample thickness, e.g., 0.3 μm or more. The layer is sometimessintered. Although permeability values are not typically provided by thesuppliers, the traces or layers formed in such conductive paint andsolder paste applications typically will individually be continuouswithin the trace or layer and impermeable to liquids and vapors.

The disclosed articles may be formed by applying a dilute coatingsolution or suspension of metal nanoparticles to an optically-responsivedetection layer and allowing the solution or suspension to dry to form asemicontinuous liquid- or vapor-permeable light-reflective layer. Thedilution level may, for example, be such as to provide a coatingsolution or suspension that will provide a suitably liquid- orvapor-permeable metal nanoparticle layer, for example solids levels lessthan 30 wt. %, less than 20 wt. %, less than 10 wt. %, less than 5% orless than 4%. By diluting an as-received commercial metal nanoparticleproduct with additional solvent and applying and drying the dilutesolution or suspension, an appreciably thin, liquid- or vapor-permeablelayer can be obtained. A variety of coating techniques can be employedto apply the metal nanoparticle solution or suspension, includingswabbing, dip coating, roll coating, spin-coating, spray coating, diecoating, ink jet coating, screen printing (e.g., rotary screenprinting), gravure printing, flexographic printing and other techniquesthat will be familiar to persons having ordinary skill in the art.Spin-coating may provide a thinner, more permeable coating than isobtained using other methods. Accordingly, some silver nanoparticlesuspensions available at low solids levels (such as 5 wt. % SVW001silver from Nippon Paint or 10 wt. % SILVERJET DGH-50 or DGP-50 fromAdvanced Nano Products) might be usable in the as-received form withoutfurther dilution if spin-coated at an appropriately high speed andtemperature onto a suitable substrate. The metal nanoparticle layer maybe sintered after it has been applied (e.g., by heating at about 125 toabout 250° C. for about 10 minutes to about 1 hour) so long as thesintering does not cause a loss of adequate permeability. It will beunderstood that the resulting reflective layer may no longer containreadily-identifiable nanoparticles, but that it may be referred to as ananoparticle reflective layer to identify the manner in which it hasbeen made.

Although liquid- or vapor-permeability may be provided by cracks, grainboundaries or other discontinuities in the metal nanoparticle layer, thedesired permeability desirably is provided by forming a porous ormicroporous layer. The average pore size may, for example, be about 0.01to about 1 μm, about 0.1 to about 0.5 μm or about 0.3 to about 100 nm.In general, larger pores are desired to impart liquid-permeability andsmaller pores are needed to provide vapor-permeability. The nanoparticlelayer may also or instead be patterned (for example, by applyingimpermeable metals) so as to create a pattern on exposure to an analyte.Selected surfaces of the nanoparticle layer may also or instead becovered or sealed off so that analyte only permeates in particularregions, again to provide a pattern on exposure.

A variety of optically-responsive detection layers may be employed inthe disclosed articles. The surface of the detection layer upon whichthe metal nanoparticle layer is formed may be flat or may containregular or irregular projections or depressions, e.g., light managementfeatures such as lenses and other structures that will be understood bypersons having ordinary skill in the art. The embodiments shown in FIG.1 through FIG. 6 provide a visibly discernible change in the appearanceof the article (e.g., a change in color such as from green to red, anappearance or disappearance of color such as from white or black tocolored or from colored to white or black, or a change from white toblack or from black to white) to indicate the presence of the desiredanalyte. This represents a preferred embodiment that can provide ameaningful optical response without requiring external electronics,instrumentation or other components. A variety of detection layers maybe employed, including not only those that provide such a visiblydiscernible appearance change but also others that may require externalelectronics, instrumentation or other components to indicate that thedesired optical response has taken place. Suitable optical responsesinclude changes in optical thickness, reflectivity, phase shift,polarization, birefringence, light transmission and other opticalparameters that will be known to persons having ordinary skill in theart. Representative detection layers are disclosed, for example, in U.S.Pat. Nos. 4,778,987 (Saaski et al. '987), 4,945,230 (Saaski et al.'230), 5,611,998 (Aussenegg et al.), 5,783,836 (Liu et al.), 6,007,904(Schwotzer et al.), 6,130,748 (Kruger et al.) and 6,590,665B2 (Painchaudet al.); in Published PCT Application No. WO 2004/057314A2 (FisoTechnologies Inc.); and in Published U.S. Patent Application Nos. US2004/0062682A1 (Rakow et al. '682) and US 2004/0184948 A1 (Rakow et al.'948), and in the above-mentioned U.S. Patent Application PublicationNo. 2007/0141580A1.

The detection layer may be homogeneous or heterogeneous, and may, forexample, be made from a mixture of inorganic components, a mixture oforganic components, or a mixture of inorganic and organic components.Detection layers made from a mixture of components may provide improveddetection of groups of analytes. The detection layer may be porous ornon-porous. The detection layer desirably is porous, especially whenused in proximity to a layer or body of sorbent media. Porosity can beobtained by using porous materials such as foams made from high internalphase emulsions, such as those described in U.S. Pat. No. 6,573,305 B1(Thunhorst et al.). Porosity may also be obtained via carbon dioxidefoaming to create a microporous material (see “Macromolecules”, 2001,vol. 34, pp. 8792-8801), or by nanophase separation of polymer blends(see “Science”, 1999, vol. 283, p. 520). For detection layers that willprovide a colorimetric indication of the presence of an analyte, thepore diameters preferably are smaller than the peak wavelength of thedesired indicator coloration. For detection layers that will be usedproximate a layer or body of sorbent media, the pores have a range ofpore sizes or a surface area selected to provide liquid or vaporsorption characteristics like those of the sorbent media. Nano-sizedpores are preferred for some applications, e.g., with average pore sizesof about 0.5 to about 20 nm, 0.5 to about 10 nm, or 0.5 to about 5 nm.

Representative inorganic detection layer materials include poroussilica, metal oxides, metal nitrides, metal oxynitrides and otherinorganic materials that can be formed into transparent (and if desiredporous) layers of appropriate thickness for producing a suitable opticalresponse such as a colorimetric change by optical interference. Forexample, the inorganic detection layer materials may be silicon oxides,silicon nitrides, silicon oxynitrides, aluminum oxides, titanium oxides,titanium nitride, titanium oxynitride, tin oxides, zirconium oxides,zeolites or combinations thereof. Porous silica is an especiallydesirable inorganic detection layer material due to its robustness.

Porous silicas may be prepared, for example, using a sol-gel processingroute and made with or without an organic template. Exemplary organictemplates include surfactants, e.g., anionic or nonionic surfactantssuch as alkyltrimethylammonium salts, poly(ethyleneoxide-co-propyleneoxide) block copolymers and other surfactants or polymers that will beapparent to persons having ordinary skill in the art. The sol-gelmixture may be converted to a silicate and the organic template may beremoved to leave a network of micropores within the silica.Representative porous silica materials are described in Ogawa et al.,Chem. Commun. pp. 1149-1150 (1996), in Kresge et al., Nature, Vol. 359,pp. 710-712 (1992), in Jia et al., Chemistry Letters, Vol. 33(2), pp.202-203 (2004) and in U.S. Pat. No. 5,858,457 (Brinker et al.). Avariety of organic molecules may also be employed as organic templates.For example, sugars such as glucose and mannose may be used as organictemplates to generate porous silicates, see Wei et al, Adv. Mater. 1998,Vol. 10, p. 313 (1998). Organo-substituted siloxanes ororgano-bis-siloxanes may be included in the sol-gel composition torender the micropores more hydrophobic and limit sorption of watervapor. Plasma chemical vapor deposition may also be employed to generateporous inorganic detection materials. This methodology generallyinvolves forming an analyte detection layer by forming a plasma fromgaseous precursors, depositing the plasma on a substrate to form anamorphous random covalent network layer, and then heating the amorphouscovalent network layer to form a microporous amorphous random covalentnetwork layer. Examples of such materials are described in U.S. Pat. No.6,312,793 (Grill et al.) and U.S. Patent Application Publication2007/0141580A1 (David et al.).

Representative organic detection layer materials include polymers,copolymers (including block copolymers) and mixtures thereof prepared orpreparable from classes of monomers including hydrophobic acrylates andmethacrylates, difunctional monomers, vinyl monomers, hydrocarbonmonomers (olefins), silane monomers, fluorinated monomers, hydroxylatedmonomers, acrylamides, anhydrides, aldehyde-functionalized monomers,amine- or amine salt-functionalized monomers, acid-functionalizedmonomers, epoxide-functionalized monomers and mixtures or combinationsthereof. The above-mentioned U.S. Patent Application Publication No. US2004/0184948A1 contains an extensive list of such monomers and referenceis made thereto for further details. Polymers having intrinsicmicroporosity (“PIMs”) provide particularly desirable detection layers.PIMs typically are non-network polymers that form microporous solids.Due to their typically highly rigid and contorted molecular structures,PIMs are unable to fill space efficiently, thus providing the disclosedmicroporous structure. Suitable PIMs include, but are not limited to,polymers disclosed in “Polymers of intrinsic microporosity (PIMs):robust, solution-processable, organic microporous materials,” Budd etal., Chem. Commun., 2004, pp. 230-231. Additional PIMs are disclosed inBudd et al., J. Mater. Chem., 2005, 15, pp. 1977-1986, in McKeown etal., Chem. Eur. J. 2005, 11, No. 9, 2610-2620 and in Published PCTapplication No. WO 2005/012397A2 (McKeown et al.).

One or more polymers within an organic detection layer may be at leastpartially crosslinked. Crosslinking may be desirable in some embodimentsbecause it can increase mechanical stability and sensitivity to certainanalytes. Crosslinking can be achieved by incorporating one or moremultifunctional monomers into the detection layer, by subjecting thedetection layer to, e.g., electron beam or gamma ray treatment, byadding or forming coordination compounds or ionic compounds in thedetection layer, or by forming hydrogen bonds in the detection layer. Inone exemplary embodiment, crosslinking is carried out in the presence ofa porogen which may be subsequently extracted from the crosslinkedsystem to yield a porous detection layer. Suitable porogens include, butare not limited to, inert organic molecules, such as normal alkanes(e.g., decane) or aromatics (e.g., benzene or toluene). Othercrosslinked polymers include the above-mentioned highly crosslinkedstyrenic polymers.

If desired, the detection layer material may be treated to modify itssurface properties or adsorption characteristics. A variety of suchtreatments may be employed, e.g., by exposing the micropores of aninorganic detection layer to a suitable organosilane compound. Thedetection layer may also or instead be treated with a suitable adhesionpromoting material (e.g., a tie layer made of titanium or anothersuitable metal) to promote adhesion between an adjacent layer (e.g., asemireflective or reflective layer) and the detection layer.

For many applications, the detection layer desirably is hydrophobic.This will reduce the chance that water vapor (or liquid water) willcause a change in the detection layer optical response and interferewith the detection of an analyte, for example, the detection of organicsolvent vapors.

The detection layer may be made from a single layer or from two or moresublayers. The sublayers may have a variety of configurations. Forexample, they may be stacked or arranged side by side. The sublayers mayalso be made from different materials selected to absorb differentanalytes. A layer or one of a set of sublayers may be discontinuous orpatterned. The pattern may create or remove a colored image, word ormessage upon exposure to an analyte, thereby providing an easilyidentifiable warning for a user. Layer or sublayer patterns may also beformed by providing one or more portions that are reactive to aparticular analyte and one or more portions that are non-reactive to thesame analyte. A pattern of reactive material may also be deposited on alarger non-reactive sublayer, e.g., by making the patterned layersufficiently thin so that no difference in optical thickness is apparentuntil an analyte is absorbed. The thickness of the detection layer mayalso be patterned, e.g., as described in U.S. Pat. No. 6,010,751 (Shawet al.). This can permit a pattern to disappear (for example when athinner portion swells to the same thickness as a thicker portion) or toappear (for example, when a portion shrinks to a lesser thickness thanan adjacent portion).

The disclosed devices may be configured in a variety of relationshipswith respect to an analyte. For example, by configuring such a device inproximity to a suitable sorbent material so that it covers the fulllength of the liquid or vapor flow path through the material, anappearance change (e.g., a color change) “front” can advance with theflow of liquid or vapor through the sorbent material past the device.The advancing appearance change front could for example continuouslyindicate the remaining service life for the sorbent material (like a bargauge or fuel gauge). The device could also be configured to givewarning only at a desired remaining service life percentage. The devicemay if desired include a pattern or reference color to assist in visualdiscernment of changes in the appearance of the device. As mentioned,appearance changes in the device may be visibly monitored under ambientlighting. The device could be illuminated using an external light sourcesuch as a light emitting diode (LED) and evaluated using a photodetectorto provide an optoelectronic signal. Whether viewed under ambient lightor by using an external light source and photodetector, the breadth ofanalyte detection could if desired be increased in a variety of ways.For example, a small array of indicators traversing the liquid or vaporflow path could be employed. Each indicator could contain differentdetection layer materials (e.g., a silica detection layer, a detectionlayer applied by plasma-activated chemical vapor deposition (“PCVD”),and a detection layer made from PIMs. Also, a series of indicators couldcontain the same detection layer material (e.g., silica) treated using aseries of different chemical treatments to provide a range of sorptiveproperties.

The disclosed devices may if desired be used in proximity to sorbentmedia capable of sorbing analytes expected to be present under theintended use conditions. The sorbent media desirably will besufficiently porous to permit the ready flow of a liquid or vapor ofinterest therethrough, and may be in the form of a finely-divided solid(e.g., powder, beads, flakes, granules or agglomerates) or porous solid(e.g., an open-celled foam). Preferred sorbent media materials includeactivated carbon; alumina and other metal oxides that can remove aliquid or vapor of interest by adsorption; clay and other mineralstreated with acidic solutions such as acetic acid or alkaline solutionssuch as aqueous sodium hydroxide; molecular sieves and other zeolites;other inorganic sorbents such as silica; and organic sorbents includinghypercrosslinked systems, such as the highly crosslinked styrenicpolymers known as “Styrosorbs” (as described for example in V. A.Davankov and P. Tsyurupa, Pure and Appl. Chem., vol. 61, pp. 1881-89(1989) and in L. D. Belyakova, T. I. Schevchenko, V. A. Davankov and M.P. Tsyurupa, Adv. in Colloid and Interface Sci. vol. 25, pp. 249-66,(1986)). Activated carbon and alumina are particularly preferred sorbentmedia. Mixtures of sorbent media can be employed, e.g., to absorbmixtures of liquids or vapors of interest. If in a finely divided form,the sorbent particle size can vary a great deal and usually will bechosen based in part on the intended service conditions. As a generalguide, finely-divided sorbent media particles may vary in size fromabout 4 to about 3000 micrometers average diameter, e.g., from about 30to about 1500 micrometers average diameter. Mixtures of sorbent mediaparticles having different size ranges can also be employed, (e.g., in abimodal mixture of sorbent media particles or in a multilayerarrangement employing larger sorbent particles in an upstream layer andsmaller sorbent particles in a downstream layer). Sorbent media combinedwith a suitable binder (e.g., bonded carbon) or captured on or in asuitable support such as described in U.S. Pat. Nos. 3,971,373 (Braun etal.), 4,208,194 (Nelson) and 4,948,639 (Brooker et al.) and in U.S.Patent Application Publication No. 2006/0096911 A1 (Brey et al.) mayalso be employed.

The disclosed devices may be rigid or flexible. Flexible devicesdesirably are sufficiently bendable without fracturing so that they canbe made using one or more roll processing steps, and if need be bent inuse, e.g., around the inside of a cartridge or other enclosure. Thedevice may be attached to a support or other component using a varietyof techniques, including film or bulk adhesives, mechanical inserts,thermal bonding, ultrasonic welding and combinations thereof.

A substrate is optional, but when present it may be made from a varietyof materials capable of providing a suitably transparent support for thedisclosed device. The substrate may be rigid (e.g., glass) or flexible(e.g., a plastic film that may be handled in one or more roll processingsteps). If made of a flexible material such as a suitably transparentplastic, the substrate may desirably have sufficiently low liquid- orvapor-permeability so that the liquid(s) or vapor(s) of interest willnot be transmitted into or out of the disclosed device through thesubstrate. A porous substrate may, for example, be placed between thedisclosed device and a layer or body of sorbent media.

Some of the disclosed devices include both semireflective and reflectivelayers. One or both of the semireflective and reflective layers may bemade using a solution or suspension of metal nanoparticles. Thesemireflective or reflective layers may each be made from a variety ofother materials that provide diffuse or preferably specular lightreflection and if need be can cooperate when appropriately spaced apartto provide a readily visibly perceptible indicator appearance change.Suitable semireflective and reflective layer materials include metalssuch as aluminum, chromium, gold, nickel, silicon, silver, palladium,platinum, titanium and alloys containing such metals; metal oxides suchas chrome oxide, titanium oxide and aluminum oxide; and the multilayeroptical films (including birefringent multilayer optical films)described in U.S. Pat. Nos. 5,699,188 (Gilbert et al.), 5,882,774 (Jonzaet al.) and 6,049,419 (Wheatley et al.), and PCT Published ApplicationNo. WO97/01778 (Ouderkirk et al.). The semireflective and reflectivelayers may be the same or different. If desired, discontinuities may beformed in one or both of the semireflective or reflective layers in thepattern of a shape, letter, symbol, or message. This can cause adiscernible pattern to emerge or disappear upon exposure to the vapor(s)of interest. A viewer may find it easier to discern the contrastingcolor of such a pattern than to discern a colorimetric change in theoverall device. When used, the semireflective layer is less reflectivethan the reflective layer and transmits some incident light. Thesemireflective layer may, for example, have a physical thickness ofabout 2 to about 50 nm, light transmission at 500 nm of about 20 toabout 80%, and reflectance at 500 nm of about 80 to about 20%. Thereflective layer may, for example, have a physical thickness of about 1to about 500 nm, light transmission at 500 nm of about 0 to about 80%,and reflectance at 500 nm of about 100 to about 20%. The faces of pairedsemireflective and reflective layers desirably are flat to within about±10 nm.

The disclosed devices may include additional layers or elements ifdesired. For example, a porous layer of sorbent-loaded composite (e.g.,a web of activated carbon particles ensconced in a matrix of fibrillatedPTFE such as is described in the above-mentioned U.S. Pat. No.4,208,194) may be placed between a semireflective or reflective layerand a layer or body of sorbent media, to homogenize vapors permeatinginto the device or otherwise moderate the optical response to conditionsin the sorbent media.

The disclosed devices may be used for a variety of applicationsincluding chemical or biological sensors, organic vapor respirators,powered air purifying respirators (PAPRs), hazmat suits, collectiveprotection filters and other applications that will be familiar topersons having ordinary skill in the art.

The invention is further illustrated in the following illustrativeexamples, in which all parts and percentages are by weight unlessotherwise indicated. The abbreviations shown below in Table 1 wereemployed in some of the examples:

TABLE 1 ABBREVIATION DESCRIPTION BC bis-catechol;5,5′,6,6′-tetrahydroxy-3,3,3′3′- tetramethyl-1,1′-spirobisindane FAfluorinated arene; tetrafluoroterephthalonitrile DMFN,N-dimethylformamide THF Tetrahydrofuran

Example 1

A thin film indicator was prepared using polymers of intrinsicmicroporosity (PIMs) as the detection layer, an Au/Pd semireflectivelayer, and a silver nanoparticle vapor-permeable reflective layer. PIMpolymer was prepared from the monomers BC and FA generally according tothe procedure reported by Budd et al. in Advanced Materials, 2004, Vol.16, No. 5, pp. 456-459. 9.0 grams of BC were combined with 5.28 g of FA,18.0 g potassium carbonate, and 120 milliliters of DMF and the mixturewas reacted at 70° C. for 24 hours. The resulting polymer was dissolvedin THF, precipitated three times from methanol, and then dried undervacuum at room temperature. A yellow solid product was obtained having amolecular weight (Mw) of 61,800.

A glass slide was sputter coated with a 5 nm thick layer of Au/Pd, usinga DENTON™ Vacuum Desk II sputter coater from Denton Vacuum equipped withan Au/Pd target with a 60:40 Au:Pd mass ratio. The sputter coating powerand coating duration were 35 milliamps and 20 seconds respectively,under a vacuum of 100 millitorr. The PIM polymer was then spin-coatedonto the Au/Pd layer using a 4% solution of the above-described PIMpolymer in chlorobenzene coated onto the Au/Pd layer at 750 rpm. Next,two different indicators were prepared by applying a silver nanoparticlesuspension to the PIM polymer layer. Indicator A was prepared usingNPS-J silver nanoparticle suspension (60% in tetradecane) from HarimaCorporation. Transmission Electron Microscopy (TEM) analysis of theparticles revealed a size distribution of approximately 2 to 10 nm indiameter. A 0.08 g quantity of the as-received nanoparticle suspensionwas mixed with 2 milliliters of heptane to provide a diluted suspensioncontaining about 3.3% silver. The diluted suspension was spin-coatedonto the PIM film at 500 rpm to provide a vapor-permeable reflectivelayer having a reflectivity of about 62% at 500 nm relative to a 100 nmthick aluminum reference layer. Indicator B was prepared using SVE 102silver nanoparticle suspension (30% in ethanol, 30 nm mean particlediameter) from Nippon Paint (America) Corporation. A 0.7 g quantity ofthis as-received suspension was mixed with 2 milliliters of ethanol toprovide a diluted suspension containing about 9.1% silver. The dilutedsuspension was spin-coated onto the PIM film at 1000 rpm to provide avapor-permeable nanoparticle reflective layer having a reflectivity ofabout 70% at 500 nm relative to a 100 nm thick aluminum reference layer.

To assess the ability of the resulting thin film indicators to competewith microporous carbon for adsorption of organic vapors, the indicatorswere placed upon a small piece of carbon-loaded blown microfiber (BMF)nonwoven web, with the vapor-permeable nanoparticle reflective layer incontact with the web and its microporous carbon. The carbon-loaded BMFweb contained 40×140 mesh activated carbon granules derived from coconutshells (from Pacific Activated Carbon Co.), dispersed throughout anelastic fibrous web made from IROGRAN™ PS 440-200 thermoplasticpolyurethane (from Huntsman International LLC), prepared as described inU.S. Patent Application Publication No. US 2006/0096911A1 (Brey et al.).The fibrous web had a 17 micrometer effective fiber diameter and a 500g/m² carbon loading level, corresponding to about a 0.22 g/cm³ carbondensity. When at equilibrium with 1000 ppm of cyclohexane flowing at 32liters/min, the carbon in this nonwoven web layer adsorbs about 0.21 gcyclohexane per g carbon. The indicators were illuminated and observedthrough the glass substrate using a spectrometer and fiber opticreflection probe while toluene vapor passed through the carbon-loadedlayer and past the indicator. In FIG. 7, Curve A and Curve Brespectively represent the initial signal and the signal at 50 ppmtoluene for indicator A. Similarly, in FIG. 8, Curve A and Curve Brespectively represent the initial signal and the signal at 50 ppmtoluene for indicator B. Indicator A exhibited a peak signal wavelengthshift of about 20 nm (from about 564 nm to about 584 nm) when challengedwith 50 ppm toluene. Indicator B exhibited a peak signal wavelengthshift of about 17 nm (from about 544 nm to about 561 nm) when challengedwith 50 ppm toluene. Indicators A and B both maintained their sorptivefunctionality when placed in thermodynamic competition with microporouscarbon.

Example 2

Using the method of Example 1, 1 mm thick glass slides were sputtercoated with a 5 nm thick layer of Au/Pd, followed by spin-coating (at1500 rpm) a layer of PIM polymer onto the Au/Pd layer. Using the methodof Example 1 (Indicator B), a diluted SVE 102 silver nanoparticlesuspension was spin-coated onto the PIM film to provide avapor-permeable nanoparticle reflective layer. The resulting thin-filmindicator had a green-yellow appearance when visually observed throughthe glass slide. DYMAX™ No. OP-4-20641A UV-cure optical adhesive fromDymax Corporation was used to adhere the indicator to the insidesidewall of a filtration cartridge made from clear polycarbonate resin,with the vapor-permeable nanoparticle reflective layer facing thecartridge interior. The cartridge was filled with 45.7 g of activatedcarbon sorbent. Several small holes were drilled in the cartridge coverimmediately above and upstream from the indicator to ensure adequatevapor flow at the indicator/sorbent bed interface. The cartridge waschallenged using 50 ppm toluene in dry air (<3% RH) flowing at 64liters/min. The indicator was monitored through the polycarbonatecartridge body at 50-60% of the bed depth using a fiber optic reflectionprobe having a <1 mm illumination spot diameter and an Ocean Opticsspectrometer. Between 6 and 16 hours after the start of the toluenechallenge, the indicator exhibited a gradual red-shift in colorationamounting to 14 nm in total. Taking into account the indicator'sposition in the cartridge, the timing and magnitude of the indicatorresponse were consistent with separately-collected concentration dataobtained using a MULTIRAE™ IR photo-ionization detector from RAE SystemsInc. positioned at the cartridge outlet. The indicator data and IRphoto-ionization detector data are plotted in FIG. 9.

A second cartridge was assembled in the same fashion and challenged with500 ppm styrene in dry air (<3% RH) flowing at 64 liters/min. A QX5™computer microscope from Digital Blue Corporation was angularly adjustedso that the indicator initially appeared green when observed, and usedto record the indicator's appearance when challenged with styrene vapor.As the challenge progressed, the indicator's initial green colorationchanged to orange along a color change front that moved from thecartridge inlet towards its outlet. An RGB histogram of the initialgreen coloration returned mean values of r=145, g=191, and b=121. Afterthe indicator responded to the styrene vapor by changing from green toorange, the histogram values were r=208, g=179, and b=127. FIG. 10 showsa black and white rendering of the indicator coloration part-way throughthe experiment and illustrates the vapor wavefront progression andappearance. The green and orange visible portions are identified withthe letters G and O, the wavefront is identified with the letter W andthe styrene flow direction is identified with the letter S.

Example 3

Using the method of Example 1, PIM polymer was prepared from themonomers BC and FA. Using a CHA Industries Mark-50 evaporator operatedat a base pressure of 1×10⁻⁵ torr and No. T-2003 titanium pellets(99.995% purity, 6×6 mm, from Cerac Inc.), cleaned glass slides weremetallized with a 10 nm thick semireflective Ti layer. A 4% solution ofthe PIM polymer in chlorobenzene was spin-coated onto the Ti layer at1000 rpm. Using the method of Example 1 (Indicator B), a diluted SVE 102silver nanoparticle suspension was spin-coated onto the PIM film toprovide a vapor-permeable reflective layer. Following silvernanoparticle deposition, the film sample was heated at 150° C. in airfor 1 hour. The resulting thin-film indicator had a green appearancewhen visually observed through the glass slide. DYMAX™ No. OP-4-20641AUV-cure optical adhesive was used to adhere the indicator to anadditional glass slide layer. The resulting glass slide stack wasadhered to the inner sidewall of a filtration cartridge made from clearpolycarbonate plastic. Next, using a method like that described in U.S.Pat. No. 4,153,661 (Ree et al.) and Example 1 of U.S. Pat. No.4,208,194, a dough was formed by combining an aqueouspolytetrafluoroethylene (“PTFE”) particle dispersion with finely ground,activated carbon particles. The dough was milled and dried but notcalendared to provide a composite web of activated carbon particlesensconced in a matrix of fibrillated PTFE. A layer of the carboncomposite web was attached to the top edge of the glass slide stack andfolded down to cover the porous nanoparticle reflective layer. Theremaining filtration cartridge volume was then filled with 45.8 g ofactivated carbon sorbent. Several small holes were drilled in thecartridge cover immediately above and upstream from the indicator toensure adequate vapor flow at the indicator/sorbent bed interface. Thecartridge was challenged with 200 ppm styrene in dry air (<3% RH) at a32 liters/min flowrate. Using ambient lighting, a TRENDnet™ ModelTV-IP201W wireless camera (from TRENDnet Company) was angularly adjustedso that the indicator initially appeared green when observed, and usedto record the indicator's appearance when challenged with styrene vapor.As the experiment progressed, the indicator color changed from theinitial green color to deep red, with the color change appearing firstnear the filtration cartridge inlet and moving towards the cartridgeoutlet. When the vapor flow was stopped, the wavefront blurred slightlybut did not move closer to or farther from the cartridge outlet. An RGBhistogram of the initial green color returned mean values of r=30, g=99,and b=51. After the indicator responded to the styrene vapor by changinggreen to red, the histogram values were r=97, g=56, and b=66. FIG. 11shows a black and white rendering of the indicator coloration part-waythrough the experiment and illustrates the vapor wavefront progressionand appearance. The carbon sorbent is identified with the letter C, thegreen and red visible indicator portions are identified with the lettersG and R, the wavefront is identified with the letter W and the styreneflow direction is identified with the letter S. The wavefront wasnoticeably more uniform than the wavefront in FIG. 10, which involved afiltration cartridge that did not include a carbon composite web betweenthe indicator and the sorbent media.

Example 4

Using the method of Example 3, a 10 nm thick titanium semireflectivelayer was evaporatively coated onto a cleaned glass slide. The Ti-coatedglass slide was next mounted onto a planar electrode. The electrode wasin turn mounted in an aluminum vacuum chamber equipped withturbomolecular pump in series with a Roots blower and a dry mechanicalpump. The chamber was closed and pumped down to a base pressure of0.0005 Torr. A mixture of tetramethylsilane, oxygen and butadiene gaseswas introduced into the chamber at respective flow rates of 100 standardcubic centimeters per minute (sccm), 100 sccm and 160 sccm. A plasma wasformed by powering the planar electrode using a Model RF50S radiofrequency power supply (from RF Power Products) operating through aModel AMN3000 impedance matching network (from PlasmaTherm Inc.). Whilethe plasma was in operation the delivered power was maintained at 75watts and the chamber pressure was maintained at 37 mTorr. Depositionwas carried out for 14 minutes to yield a plasma-deposited thin organicfilm having a 0.768 micrometer thickness. The plasma-deposited thin filmwas annealed in a vacuum furnace at a temperature of 450° C. for 1 hourto provide a microporous thin film detection layer atop the titaniumsemireflective layer. A 0.0475 g quantity of SILVER NANOINK™ silvernanoparticle slurry in methanol (Lot S Ag 031027W, from Advanced NanoProducts Co., Ltd, Korea) was diluted with an additional 2 millilitersof methanol to provide a dilute suspension which was spin-coated ontothe thin film detection layer at 1500 rpm. The resulting spin-coatedsilver nanoparticle layer was allowed to dry, yielding a vapor-permeablethin film silver nanoparticle reflective layer atop the thin filmdetection layer.

To assess the ability of the resulting indicator to compete withmicroporous carbon for adsorption of organic vapors, the indicator wasplaced upon a small piece of the carbon composite web employed inExample 3, with the permeable nanoparticle reflective layer in contactwith the carbon composite web. The indicator appearance was observedthrough the glass substrate using a spectrometer and fiber opticreflection probe to evaluate the sensor coloration. The sensor wasexposed to toluene, methyl ethyl ketone and ethylbenzene vapor streamspassing through the carbon composite web. The toluene and methyl ethylketone streams were maintained at less than 5% relative humidity and theethylbenzene stream was maintained at 82% relative humidity. The resultsare shown in FIG. 12, where Curves A, C and D respectively show themethyl ethyl ketone, toluene and ethylbenzene vapor concentration vs.the observed wavelength shift, and where Curve B shows the toluene vaporconcentration vs. the observed wavelength shift when the carboncomposite web was not employed. The results in FIG. 12 show that thedisclosed indicator exhibited significant wavelength shifts for allvapors. Curves B and C show that the disclosed indicator exhibitedwavelength shifts of about 6 to 16 nm at a 200 ppm vapor concentration,and wavelength shifts of about 12 to 21 nm at a 2000 ppm vaporconcentration. Curves B and C also show that the porous detection layerin the disclosed indicator maintained its sorptive capability even whenplaced in thermodynamic competition with microporous carbon.

Example 5

Using the method of Example 1, PIM polymer was prepared from themonomers BC and FA. Using a CHA Industries Mark-50 evaporator operatedat a base pressure of 1×10⁻⁵ torr and No. T-2003 titanium pellets,cleaned glass slides were metallized with a 10 nm thick semireflectivelayer of Ti. A 4% solution of the PIM polymer in chlorobenzene wasspin-coated onto the Ti layer at 2000 rpm. Using the method of Example 1(Indicator B), a diluted SVE 102 silver nanoparticle suspension wasspin-coated onto the PIM film and dried under vacuum at room temperaturefor 12 hours to provide a multilayer thin-film indicator with a PIMdetection layer located between a titanium semireflective layer and avapor-permeable metal nanoparticle reflective layer. The indicator had agreen appearance when visually observed through the glass slide andsemireflective layer.

To assess the ability of the indicator to compete with microporouscarbon for adsorption of organic vapors, the indicator was placed upon asmall piece of carbon-loaded nonwoven web containing about 500 g/m²(corresponding to an effective carbon density of about 0.22 g/cc) of40×140 mesh activated carbon granules derived from coconut shells (fromPacific Activated Carbon Co.), dispersed throughout an elastic fibrousweb made from IROGRAN™ PS 440-200 thermoplastic polyurethane (fromHuntsman International LLC), prepared as described in U.S. PatentApplication Publication No. US 2006/0096911A1 (Brey et al.). Atequilibrium with 1000 ppm of cyclohexane flowing at 32 liters/min, thecarbon in the layer adsorbs 0.21 g cyclohexane per gram of carbon. Theindicator appearance was observed through the glass substrate using aspectrometer and fiber optic reflection probe, and measured in dry air(<3% RH) and at 85% relative humidity. The indicator exhibited only a 3nm spectral shift at 85% relative humidity compared to the results indry air, thus demonstrating that the indicator was generally insensitiveto high humidity conditions. Next, while maintaining an 85% relativehumidity atmosphere, the carbon-loaded nonwoven web was exposed tostyrene vapor at 20 ppm. The indicator exhibited a 23 nm spectral shift,demonstrating that the indicator maintained its sorptive functionalitywhen placed in thermodynamic competition with microporous carbon exposedto a humid analyte stream.

Example 6

Using the method of Example 5, a 10 nm thick titanium semireflectivelayer was evaporatively coated onto two cleaned glass slides. PIMpolymer with a weight average molecular weight (Mw) of 62,900 wasprepared using the method of Example 1 and the monomers BC and FA. A3.2% solution of the PIM polymer in a 60/40chlorobenzene/tetrahydropyran mixture was spin-coated onto the Ti layersof the coated glass slides at 1000 rpm. A 1.0 g quantity of SILVERJET™DGP 40LT-25C silver nanoparticles (43.25% in methanol, from AdvancedNano Products Co., Ltd., Korea) was added to 2 milliliters methanol togive a diluted suspension containing 16.8% solids. The dilutedsuspension was spincoated at 600 rpm onto the PIM layer on each coatedslide. One slide was then air dried and identified as indicator A. Theother slide was heated at 150° C. for 1 hour in air to partially sinterthe silver particles and identified as indicator B. Indicator B had areflectivity of about 39% at 500 nm relative to a 100 nm thick aluminumreference layer.

To assess the abilities of both indicators to compete with microporouscarbon for adsorption of organic vapors, the coated side of each slidewas placed against a small piece of the carbon-loaded web 94 used inExample 2, with the permeable nanoparticle reflector in contact with thecarbon-loaded web. The indicators were observed through the glasssubstrate and semireflective layer using a spectrometer and fiber opticreflection probe. The indicators were exposed to a 50 ppm toluene vaporstream passing through the carbon-loaded web. The spectral peak forIndicator A shifted from 532 nm to 558 nm, and the spectral minimum forIndicator B shifted from 609 nm to 629 nm, demonstrating that in eachinstance the indicator maintained sorptive functionality when placed inthermodynamic competition with microporous carbon.

All patents and patent applications cited above, including those in theBackground section, are incorporated by reference into this document intotal. To the extent that there is a conflict, this document willprevail.

A number of embodiments of the invention have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the invention. Accordingly, otherembodiments are within the scope of the following claims.

1. A method for forming an optically-responsive multilayer reflectivearticle, which method comprises applying a dilute solution or suspensionof metallic nanoparticles to an optically-responsive detection layer andallowing the solution or suspension to dry to form a semicontinuousliquid- or vapor-permeable light-reflective layer that will permit aliquid or vapor analyte to pass through the light-reflective layer tocause an optically-responsive change in the detection layer in thepresence of the analyte.
 2. A method according to claim 1 wherein thedilute solution or suspension has a solids level less than 30%.
 3. Amethod according to claim 1 wherein the dilute solution or suspensionhas a solids level less than 10%.
 4. A method according to claim 1wherein the dilute solution or suspension has a solids level less than5%.
 5. A method according to claim 1 wherein the nanoparticles comprisesilver or an alloy containing silver.
 6. A method according to claim 1wherein the nanoparticles comprise nickel, gold, platinum, palladium oran alloy containing any of the foregoing.
 7. A method according to claim1 wherein the nanoparticles have an average particle diameter of about 3to about 50 nm.
 8. A method according to claim 1 wherein thelight-reflective layer has a thickness less than about 200 nm.
 9. Amethod according to claim 1 wherein the light-reflective layer has athickness less than about 100 nm.
 10. A method according to claim 1wherein the light-reflective layer is discontinuous.
 11. A methodaccording to claim 1 wherein the light-reflective layer issemicontinuous.
 12. A method according to claim 1 wherein thelight-reflective layer has a reflectance of at least about 20% at 500nm.
 13. A method according to claim 1 wherein the light-reflective layerhas a reflectance of at least about 50% at 500 nm.
 14. A methodaccording to claim 1 further comprising sintering the light-reflectivelayer.
 15. A method according to claim 1 wherein the detection layer isporous.
 16. A method according to claim 15 wherein the detection layercomprises porous silica.
 17. A method according to claim 1 furthercomprising forming the detection layer by plasma-activated chemicalvapor deposition.
 18. A method according to claim 1 wherein thedetection layer comprises a polymer of intrinsic microporosity.
 19. Amethod according to claim 18 wherein the detection layer comprises apolymer of bis-catechol and a fluorinated arene.
 20. A method accordingto claim 1 wherein the detection layer exhibits a change in opticalthickness in the presence of an analyte.
 21. A method according to claim1 wherein the detection layer exhibits a change in light phase shift,polarization, birefringence or transmission in the presence of ananalyte.